Addendum to the Operating Instructions

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ Services * _0818* Addendum to the Operating Instructions Safety Encoders and Safety Brakes DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors Functional Safety Edition 08/ /EN

2 SEW-EURODRIVE Driving the world

3 Table of contents Table of contents 1 General information How to use this documentation Content of the documentation Other applicable documentation Safety notes Preliminary information Designated use Inspection/maintenance Functional safety (FS) Functionally safe motor options FS mark Retraceability Underlying standards TÜV certification Safety functions Requirements to the follow-up electronics Brake diagnostics Motor combinations Validation Motor structure Nameplates Mechanical installation Manual brake release Electrical installation Connecting the EI7C FS encoder EI7C FS visual feedback Temperature sensor /TF Brake control Permitted brake controls Inspection/maintenance Safety encoder Removing/installing the encoder Measuring wobbling Inspection and maintenance intervals Safety brake Preliminary work for motor and brake maintenance Working steps for inspecting (E)DR , (E)DRN63 315, DR brakemotors Brake exchange Diagnostic unit /DUE for function and wear monitoring Technical data Safety encoder Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 3

4 Table of contents 8.2 Safety brake Checklists Checklist for encoder assembly Checklist for brake assembly Index Glossary Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

5 General information How to use this documentation 1 1 General information 1.1 How to use this documentation The current version of the addendum to the operating instructions is the original. This addendum to the operating instructions contains special information on functionally safe motor options (safety encoder and safety brake) of the DR.., DRN.., DR2.., EDR.., and EDRN.. motor series. In addition to the addendum to the operating instructions at hand, the following operating instructions apply for motors with safety encoders and/or safety brakes: AC motors with safety encoder and/or safety brake "DR , DRN63 315, DR AC Motors" operating instructions Explosion-proof AC motors with safety encoder "Explosion-Proof EDR AC Motors, EDRN ATEX" operating instructions or "Explosion-Proof EDR AC Motors, EDRN IECEx" operating instructions This documentation is an integral part of the product and contains important information on operation and service. The documentation is intended for all employees who assemble, install, start up, and service this product. Make sure this documentation is accessible and legible. Ensure that persons responsible for the systems and their operation as well as persons who work on the product independently have read through the documentation carefully and understood it. If you are unclear about any of the information in this documentation, or if you require further information, contact SEW EURODRIVE. Make sure you always use the latest documentation and software version. 1.2 Content of the documentation This documentation contains additional safety-related information and conditions for operation in safety-related applications. 1.3 Other applicable documentation The following publications and documents have to be observed as well: "Project Planning for BE.. Brakes DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors Standard Brake/Safety Brake" manual "DR.. Series AC Motors" catalog "DRN63 315, DR2S63 80 AC Motors" catalog Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 5

6 2 Safety notes Preliminary information 2 Safety notes 2.1 Preliminary information The following general safety notes serve the purpose of preventing injury to persons and damage to property. They primarily apply to the use of products described in this documentation. If you use additional components, also observe the relevant warning and safety notes. 2.2 Designated use DR.., DRN.., DR23.., EDR.., and EDRN.. motors with functionally safe motor options are intended for industrial systems. When installed in machines, start of the designated operation is prohibited until it is determined that the machine complies with the local laws and directives. The Machinery Directive 2006/42/EC is valid for the respective area of application. Air-cooled versions are designed for ambient temperatures of -20 C to +40 C and installation altitudes 1000 m above sea level. Any differing specifications on the nameplate must be observed. The ambient conditions must comply with all the specifications on the nameplate. In order to determine the safety integrity (performance level PL and/or safety integrity level SIL) of a system's safety functions, the system manufacturer must perform an overall evaluation. This document contains the product-related specifications necessary for the evaluation. Operation of DR.., DRN.., DR2.., EDR.., and EDRN.. motors with functionally safe motor options on third-party inverters is permitted. Before starting the designated use, make sure that the system complies with the specifications of this documentation, and in particular the technical data. 6 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

7 Safety notes Designated use Safety encoder The safety encoders described in this documentation are intended for use with DR.., DRN.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. When using a safety encoder in combination with a BE.. brake, the brake may only be used as a holding brake. Braking during operation is not permitted. The designated use of the brake is to activate the brake at standstill (< 20 min 1/min). Emergency stops from higher motor speeds are permitted. SEW EURODRIVE recommends stopping the drive with stop category 1 in accordance with EN For AS7W, AG7W, AS7Y, and AG7Y safety encoders, the absolute interface is not part of the PL d/sil 2 approval. The absolute interface may not be used solely for implementing safety functions. SEW EURODRIVE recommends activating the monitoring functions lag error, speed, and encoder monitoring when configuring the inverter. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 7

8 2 Safety notes Designated use Safety brake The safety brakes described in this documentation are intended for use with DR.., DRN.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. When using an AC motor in combination with a BE.. safety brake, the safety brake may be used only as a holding brake. The designated use is to activate the brake at standstill (< 20 min 1/min). Emergency stops from higher motor speeds are permitted. SEW EURODRIVE recommends stopping the drive with stop category 1 in accordance with EN The BE.. safety brake may only be used at an ambient temperature of -20 C to +40 C. The dimensioning of drives with the BE.. safety brake considers a maximum of 1000 emergency stop braking operations in the life cycle. A minimum pause of 6 minutes must be allowed between 2 emergency stop braking operations. Project planning clearly defines how often the system can perform the emergency stop braking. When dimensioning the BE.. safety brake, observe the valid project planning specifications and the resulting application limits of SEW EURODRIVE. If the application requirements or technical properties of the BE.. safety brake change, project planning and a check of the application limits must be performed again. It is not permitted to retrofit the BE.. safety brake or to replace an existing BE.. brake with a BE.. safety brake. The BE.. safety brake must not be exposed to the following substances/conditions: Oils Acids Gases Vapors Radiation Motors with BE.. safety brake are not suitable for operation in areas with increased vibration stress of level 1 (vibration level 1). 8 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

9 Safety notes Inspection/maintenance Inspection/maintenance Work on a drive with functionally safe motor options indicated by the FS logo on the motor nameplate can be performed by the operator. Any work on the safety encoder and/or the safety brake are carried out at your own risk. The operator is responsible and liable for the proper fulfillment of the work described in the relevant documentation. The operator has to ensure the traceability of the performed work regarding functional safety. In case of proven compliance with the work described in the operating instructions, the characteristics regarding functional safety described by the manufacturer are maintained. Use only genuine spare parts in accordance with the valid parts list for maintenance purposes. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 9

10 3 Functional safety (FS) Functionally safe motor options 3 Functional safety (FS) 3.1 Functionally safe motor options Drives from SEW EURODRIVE are also optionally available with functionally safe motor options. These options are intended for implementation of safety functions in safety-relevant applications. SEW EURODRIVE assumes responsibility for the delivered drive in terms of compliance of the functionally safe motor options with the functional safety regulations. To indicate deviations from the delivery state, any safety-relevant connecting elements are sealed General When implementing safety functions in machines, it is necessary to evaluate in particular whether the used components are suitable for performing a specific safety function. When using functionally safe motor options from SEW EURODRIVE, the following safety-related requirements, e.g. in accordance with EN ISO parts 1 and 2, are already taken into account: Application of basic safety principles Application of proven safety principles Specifications on failure probability (B 10D, MTTF D, or PFH D ) Common Cause Failure (CCF) Determination of the category (Cat.) Production monitoring with 100% final inspection Retraceability by the unique motor assignment Notice of influences and ambient conditions Compliance with normative requirements regarding documentation As an advantage for the machine designer, SEW EURODRIVE has already fulfilled these safety-relevant requirements for functionally safe motor options. In the overall analysis of safety technology, the machine designer can rely on the manufacturer's confirmation, e.g. based on the product documentation or the German Technical Inspection Association (TÜV) certificate. The internal effort required for evaluation and documentation is reduced considerably. If other components (standard components) are used for implementing safety functions, the machine designer has to evaluate the safety-related requirements Safety encoders Safety encoders from SEW EURODRIVE are characterized by their exceptional reliability as well as electronic and mechanical load capacity. Safety encoders allow you to increase the safety in your machines by implementing safety functions regarding speed, direction of rotation, idle state and relative position. The safety encoder provides the safety-relevant signals in the intelligent interaction of sensor, control and actuator. The safety function requires a reliable mechanical connection between encoder and motor. At SEW EURODRIVE, this connection is dimensioned in such a way that fault exclusion is achieved. The safety encoders cannot trigger a safe state at the machine autonomously. Therefore, they have to be monitored in the overall system. The overall system will trigger a suitable error response, e.g. the safe state, on request. 10 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

11 Functional safety (FS) FS mark Safety brake Safety brakes from SEW EURODRIVE are characterized by their exceptional reliability as well as electronic and mechanical load capacity. Safety brakes allow you to increase the safety in your machines by implementing safety functions for deceleration and stopping. The safety brake represents the safetyrelevant actuator in the intelligent interaction of sensor, control, and actuator. The safety brakes cannot trigger a safe state at the machine autonomously. The brakes have to be supplemented with a suitable brake control and monitored by brake diagnostics, if necessary. The overall system triggers a suitable error response, e.g. the safe state, on request. 3.2 FS mark Motors from SEW EURODRIVE are optionally available with functionally safe motor options. These are designed for implementation of safety functions. The documentation designates the respective functional safety design explicitly as safety encoder plus "type designation" or safety brake plus "type designation". SEW EURODRIVE labels a functionally safe motor option at the drive with an FS logo and a 2-digit number on the motor nameplate. The number is a code that indicates which components in the drive are safety-related. This allows to uniquely identify an available functionally safe motor option via the motor nameplate. FS logo Decentralized inverters Available functionally safe motor option Safety brake Safety encoder 01 X 02 X 04 X 07 X X 11 X X If the FS logo, e.g. with the code "FS-11", is present on the motor nameplate, the combination of safety encoder and safety brake is available at the motor. If an FS logo is available, adhere to the information specified in the corresponding documentation. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 11

12 3 Functional safety (FS) Retraceability 3.3 Retraceability Functionally safe motor options can be retraced by SEW EURODRIVE with the motor serial number and thus have a unique assignment to the motor. If the SEW EURODRIVE service replaces a safety encoder or a safety brake, the retraceability is ensured. If you replace a functionally safe motor option on your own, you revoke this assignment. To continue the assignment, document the replacement yourself. 3.4 Underlying standards The safety assessment of safe motor options is based on the following standards and safety classes: Safety encoders Add-on encoders: ES7S, EG7S, AS7W, AG7W, AS7Y, AG7Y Safety class/ underlying standard Safety Integrity Level (SIL) in accordance with IEC Performance Level (PL) in accordance with EN ISO Built-in encoder: EI7C FS Safety class/ underlying standard Safety Integrity Level (SIL) in accordance with EN Performance Level (PL) in accordance with EN ISO Safety brake BE03 to BE32 Safety class/ underlying standard Category (Cat.) in accordance with EN ISO Safety class SIL 3 or PL e can be achieved if a suitable functionally safe motor option is integrated into a safety system. The requirements, e.g. on the system architecture, diagnostics, and failure probabilities, are to be implemented in accordance with the normative specifications and with this documentation. 3.5 TÜV certification The following certificate is available for the described safety brakes: Certificate of the TÜV NORD Systems GmbH & Co. KG The TÜV certificate is available for download on the SEW EURODRIVE website ( 12 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

13 Functional safety (FS) Safety functions Safety functions Safety functions safety encoder ES7S, EG7S, AS7W, AG7W, AS7Y, AG7Y add-on encoders The following safety functions in accordance with EN regarding speed, direction of rotation, idle state, and relative position can be implemented in functionally safe systems with the sine/cosine interface of the safety encoders: SS1, SS2, SOS, SLS, SDI, SLI, SSR, SAR, SSM INFORMATION For AS7W, AG7W, AS7Y, and AG7Y encoders, the absolute interface is not part of the PL d/sil 2 approval. The absolute interface may not be used solely for implementing safety functions. Built-in encoder EI7C FS The following safety functions in accordance with EN regarding speed and direction of rotation can be implemented in functionally safe systems with the HTL interface of the safety encoder: SS1, SLS, SDI Safety functions of the safety brake The implementation of a safety function with brakes requires that the brake is applied on request. The safety function is activated when the brake is applied. The brake coil has to be de-energized and the energy stored in the brake coil reduced. By adding a BE.. safety brake into a safe overall system, the following safety functions can be implemented: SBA (Safe Brake Actuation) SBH (Safe Brake Hold) INFORMATION Safety functions SBA and SBH are defined by SEW EURODRIVE based on the standard EN The implementation of the SBA and SBH safety functions additionally require the safety functions SBC and STO in the overall system. For safety-related requests of the brake, SBC and STO ensure that the brake applies and that the drive does not generate a torque against the applied brake. The SBC and STO safety functions are not part of the brake and have to be additionally implemented in the overall safety system. The performance level (PL) of the SBC and STO safety functions must at least meet the required performance level (PLr) of the application. SEW EURODRIVE recommends to stop the drive using the stop category 1 according to EN prior to activating the SBC and STO safety functions. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 13

14 3 Functional safety (FS) Requirements to the follow-up electronics 3.7 Requirements to the follow-up electronics Add-on encoders: ES7S, EG7S, AS7W, AG7W, AS7Y, AG7Y The monitoring of the sine/cosine signals for detecting the safe state is performed by the follow-up electronics. The follow-up electronics has to check the sine/cosine signals of the rotary encoder for validity. For safety-related use of the encoders, the following requirements have to be fulfilled by the follow-up electronics: Designation Requirement Safety requirements SIL 2 Diagnostic coverage (DC) 90 % Error presumptions Monitoring of the phasor length "r" According to EN :2016, table D r = a + b with a = A A for cosine signals and b = B B for sine signals Safe state Phasor length "r" outside of the range 350 mv r 700 mv Terminating resistance between A and A or B and B 120 Ω ±10 % A B A 120 Ω a B 120 Ω b Terminating resistance between A, A, B, B to the supply voltage and reference ground > 1 kω Scanning frequency At least twice as high as the frequency maximally occurring in the application at the encoder signal outputs (Nyquist criterion) If the safety encoders are connected with prefabricated encoder cables from SEW EURODRIVE to the follow-up electronics from SEW EURODRIVE, these requirements have been met Integrated encoders: EI7C FS The built-in encoder EI7C FS is intended for operation with functionally safe encoder evaluation units from SEW EURODRIVE, e.g. safety option S12 or safety card MOVISAFE CSS..A. Operating the encoder with encoder evaluation units from other manufacturers is not permitted. 14 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

15 Functional safety (FS) Brake diagnostics Brake diagnostics In applications with brakes, the braking torque represents an important criterion for the functionality of the brake. In the event of a reduction in or loss of braking torque, the correct functionality of the application is no longer ensured. As a result, the safety of the machine and/or even the safety of persons may be decreased. To prevent this from happening, the brake can optionally be checked using brake diagnostics. Brake diagnostics provides the user with information about the status and performance capability of the brake. This allows you to detect potential errors in time and initiate maintenance/repair. Brake diagnostics may be required by standards, particularly in safety-related applications in accordance with EN ISO in which a safety function is implemented using a brake. The diagnostic coverage level (DC avg ) required by standards must be fulfilled depending on the required Performance Level (PL). The diagnostic coverage is a key figure of the implemented brake diagnostics. Brake diagnostics must detect the following possible failures separately for each brake: Brake is not applied. Insufficient braking torque. To prevent faulty diagnostic results, SEW EURODRIVE recommends to additionally diagnose the potential failure "Brake does not release". Brake diagnostics is not part of the brake and must be implemented within the system. SEW EURODRIVE offers the brake diagnostics solution e.g. as software for the controller of the performance classes advanced/power. Brake diagnostics fulfills the regulatory requirements and allows for solutions in up to performance level e (PL e). Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 15

16 3 Functional safety (FS) Motor combinations 3.9 Motor combinations Safety encoders The safety encoders described below are intended for use with DR.., DRN.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. Safety encoders on the DR.., DRN.. AC motor Motors Encoder Part number without with Connection cover DR..71 DR..132 DRN80 DRN132S ES7S AS7W AS7Y DR..160 DR..280 DRN132M DRN280 EG7S AG7W DR..71 DR..132 AG7Y Motors Encoder Part number DRN71 DRN132S DR EI7C FS Ordering with part number not possible Safety encoders on the EDR.., EDRN.. explosion-proof AC motor Motors Encoders without Part number with connection cover EDR..71 EDR..132 EDRN80 EDRN132S ES7S AS7W AS7Y EDR..160 EDR..280 EDRN132M EDRN280 EG7S AG7W AG7Y Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

17 Functional safety (FS) Motor combinations Safety brake Motor combinations with BE.. brake Depending on the demands placed on the brake, different brake mounting sizes with different braking torque steps are available for mounting to the respective motor. The following tables show the possible combinations of motor and brake as well as the braking torque steps for each brake to achieve the desired nominal braking torque: DR.. EDR DRN.. EDRN S 132M 132L DR BE03 BE05 BE1 BE2 BE5 BE11 BE20 BE30 BE32 BE60 BE62 BE120 BE122 Design not available as safety brake. Design available as safety brake. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 17

18 3 Functional safety (FS) Motor combinations Braking torque graduations Brake (M Bmax ) Available stages for M B Depending on the demands placed on the brake, different braking torque graduations are available depending on the brake size. The following table shows the available graduations: BE03 (3.4 Nm) 0.9 X 1.3 X 1.7 X BE05 (5 Nm) 1.8 X 2.1 X 2.5 X 2.7 X 3.4 X 3.5 X BE1 (10 Nm) BE2 (20 Nm) 5 X X X 7 X X 10 X X BE5 (55 Nm) 14 X X BE11 (110 Nm) 20 X X X 28 X X 40 X X X 55 X X X 80 X X 110 X X 150 X 200 X Brake (M Bmax ) Available stages for M B BE30 (300 Nm) 75 X BE32 (600 Nm) 100 X X 150 X X 200 X X 300 X X 400 X 500 X 600 X X Available X Not available for BE.. safety brake. INFORMATION BE20 (200 Nm) Note that for the BE.. safety brake, some of the reduced braking torque steps are not available in combination with the manual brake release option. It may be necessary to contact SEW EURODRIVE. 18 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

19 Functional safety (FS) Validation Validation The system manufacturer has to perform an overall evaluation for determining the safety of a machine. The effectiveness of each risk minimization must be checked. It must also be checked if the required safety integrity (SIL and/or PL) is reached for each implemented safety function. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 19

20 4 Motor structure Nameplates 4 Motor structure 4.1 Nameplates Motor The following figure shows an example motor nameplate with FS logo: [2] [1] R87 DRS90L4BE5/TF Inverter duty VPWM 3ph.IEC Hz r/min 1400/22 V Δ/ Y IP 54 TEFC kw 2.2 S1 A8.6/4.95 P.F.0.81 eff % 81.1 IE1 kw 2.2 S1 A 7.2/4.15 P.F.0.78 eff % 84.0 IE1 60 Hz r/min 1720/27 V Δ/ Y K.V.A.-Code H Th.Kl. 155(F) S.F. 1.0 M.L. 02 Design NEMA C Vbr AC i63.68 Nm 960/780 IM M1 Nm 40 CLP220 Miner.Öl/2.3l BST1.2S kg AMB C Made in Germany [1] Motor serial number [2] FS logo for functional safety Safety encoder The following figure shows an example encoder nameplate of a safety encoder: Baumer Hübner GmbH Max-Dohrn-Str. 2+4 D Berlin 0044 IECEx IBE X Sine Encoder OG83 S SN1024 SN: /2016 II3D Ex na IIC T4 Gc X II3D Ex tc IIIC T120 C Dc X SEW-Typ EG7S SEW-No [1] UB = VDC Vpp IP 66 [2] [6] [1] Type designation [2] Part number [3] Serial number [4] Date of manufacturing (ww/yyyy) [5] IECEx information [6] IECEx certificate number [5] [4] [3] The nameplate of a safety encoder does not show an FS logo. The design for functional safety has to be identified using the motor nameplate, see chapter "FS mark" ( 2 11). 20 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

21 Motor structure Nameplates Safety brake The following figure shows an example self-adhesive label of a safety brake with FS logo: [4] [3] [2] [1] BE20 MN: Use only with SEW-Rectifier ID: [5] [1] Identification number of the brake: 0001.: Plant : Serial number of the brake : Date of production (DDMMYY) [2] Assembly order number [3] Brake and brake size [4] Data matrix [5] FS logo Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 21

22 5 Mechanical installation Manual brake release 5 Mechanical installation INFORMATION Note that greases and oils must not be allowed on the mechanical connections of the safety components during assembly or operation. 5.1 Manual brake release If the manual brake release was ordered, the manual brake release is installed and set at the factory. INFORMATION The brake option manual brake release /HF is not permitted and must not be retrofitted. The manual brake release /HR must not be retrofitted, see corresponding operating instructions. 22 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

23 Electrical installation Connecting the EI7C FS encoder 6 6 Electrical installation INFORMATION SEW EURODRIVE recommends using prefabricated cables from SEW EURODRIVE to connect the safety encoders. 6.1 Connecting the EI7C FS encoder There is an 8-pin M12 plug connector on the terminal box for connection. M12 AVRE male, A-coded Pin 1: +U B Pin 5: B Pin 2: GND Pin 6: B Pin 3: A Pin 7: nc Pin 4: A Pin 8: nc INFORMATION Pins 7 and 8 must not be used. The encoder cable must meet the following requirements: Maximum cable length: 100 m. The cable length may be limited by the encoder evaluation unit. Minimum core cross section: 0,25 mm 2. The cable must be shielded. The shield must be connected over a large surface area at both ends. The cable must have twisted-pair conductors. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 23

24 6 Electrical installation EI7C FS visual feedback 6.2 EI7C FS visual feedback The LED display, which is visible when the fan guard is removed, provides visual feedback about the signal track state. A red LED and a green LED are used as a status display for the EI7C FS safety encoder. The green LED indicates the current status. The red LED is used to display the error history by means of a flash code. The error history always displays the most recent errors since the last time the encoder was switched on Indicating the normal state During normal operation, the green status LED lights up constantly. Usually, no error has occurred and the red error history LED is off. If an error already occurred before the current normal operating state, this is indicated by the flash code on the red LED described below Indicating an internal diagnostics error The EI7C FS encoder has a self-diagnostics system. If this diagnostics system has an error, the encoder enters an error status. The error can be reset by switching off the supply voltage and then switching it back on Indicating service mode If the encoder is supplied with a defined voltage range below the regular supply voltage range during startup, the encoder automatically goes into service mode. The output drivers are switched off. The red error history LED indicates service mode by lighting up constantly. The green status LED reports the distance between the encoder module and the fan wheel. Any service work necessary on the encoder may only be performed by SEW EURODRIVE employees Indicating error statuses The start of an error code is indicated by a long pulse (START). The number of brief flash pulses indicates the most recent error since the encoder was switched on. The long START signal does not count as part of this number. The figure shows the structure of the flash code. The "Normal operation" ( 2 25) table provides an overview of possible error statuses and the defined LED signals for these statuses. Start 1 N Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

25 Electrical installation Temperature sensor /TF LED codes for the operating statuses Normal operation Displayed status Green LED (status) Red LED (error) No voltage or defective OFF OFF Internal diagnostics error ON ON No error ON OFF No errors at the moment. Most recent error is displayed. An error has occurred. Most recent error is displayed. ON OFF Error code Error code Temperature error 1 Supply voltage error 2 Analog signal error 3 Error in digital track A or B 4 Distance difference error 5 Output driver error 6 Service operation/setup mode Status Meaning Green LED Red LED Service operation/setup mode (Defined voltage range while switching on) Amplitude OK OFF ON Amplitude is too high Flashes (approx. 2 Hz) ON Amplitude is too low Flashes (approx. 0.5 Hz) ON 6.3 Temperature sensor /TF If you use a safety brake, you must also use and evaluate the temperature sensor /TF. INFORMATION If several motors with safety brake are operated with one frequency inverter (multimotor operation), an external switching device for monitoring the temperature sensor /TF is necessary. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 25

26 6 Electrical installation Brake control 6.4 Brake control The brake is released electrically. The brake applies after the voltage is switched off. The braking or stopping takes place mechanically. These voltage disconnection types are distinguished: Functional control Control of the brake outside functional safety. Safe control Control of the brake for the use in functional safety. 6.5 Permitted brake controls The supply of the safety brake must be achieved by a brake control. There are several designs for this purpose which are either designated for installation in the motor wiring space or for installation in the control cabinet. The following supply types are not permitted for BE.. safety brake: Operation without brake control (DC direct voltage supply) Operation with third-party control Supply via motor terminal board (direct wiring) For permitted brake controls, refer to chapter "Technical data" ( 2 41). Connection may only be performed according to the valid wiring diagram enclosed. 26 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

27 Inspection/maintenance Safety encoder 7 7 Inspection/maintenance 7.1 Safety encoder Certain demands on the mechanical coupling of the encoder system to the motor must be met so that the encoder can be used for safety-relevant tasks. With the EI7C FS built-in encoder, no work may be performed on the encoder. Order the SEW EURODRIVE service to perform any necessary work on the encoder. The following options are available for performing work on all add-on encoders in safety design or on the motor when the sealed connections need to be opened: Order the SEW EURODRIVE service to perform this work. You perform the work yourself. Note that all work on the safety encoder and its mechanical coupling is carried out at your own risk. The operator is responsible and liable for the proper fulfillment of the work. The operator has to ensure the traceability of the performed changes regarding functional safety. In case of proven compliance with the activities described in the operating instructions, the characteristics regarding functional safety described by the manufacturer are maintained. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 27

28 7 Inspection/maintenance Removing/installing the encoder 7.2 Removing/installing the encoder WARNING Loss of the safety functions due to a faulty mechanical connection between the motor and the encoder. Severe or fatal injuries To ensure the exclusion of any errors in the mechanical connection between the drive component and the encoder, comply with the following points in accordance with EN : Proper (dis)assembly in accordance with this documentation. Exchange of worn or damaged components. Compliance with the tightening torques specified in this document Required tools You need the following tools to assemble and disassemble the encoders. Make sure that all the tools are available before you remove/install an encoder. For the encoders ES7S, AS7W, AS7Y, a new expansion anchor (part number: ) NOCO fluid (part number: ) Loctite 241 Various sizes of hollow hexagon wrenches Various sizes of external hexagon wrenches Torque wrench for tightening torques of 2.0 Nm to 8.0 Nm Sensor for measuring the wobble with a measuring range in the 1/100-mm range (for (E)DR , (E)DRN80 132S motors only) Removing the encoder A detailed description of the disassembly of the encoder can be found in the operating instructions of the motor. 28 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

29 Inspection/maintenance Measuring wobbling Reassembly A detailed description can be found in the operating instructions of the motor. In the case of safety encoders, please note the following working steps and the tightening torques specified in the table..s7./.g7. encoders: Apply NOCO fluid to the encoder pins. AS7./ES7. encoders: Place a new expansion anchor [362] at the torque bracket of the encoder [220]. AG7./EG7. encoders: Clean the threads of the retaining screw on the torque bracket [232] and apply Loctite 241 to the screws. ES7S EG7S Item no. Description AS7W AS7Y AG7W AG7Y Tightening torque in Nm [B] Central retaining screw 2.75 ±10 % 8 ±5 % [A]/[232] Retaining screws on the torque bracket 2.25 ±10 % 6 ±10 % [619] Connection cover screws 2.25 ±10 % 2.25 ±10 % In the case of the ES7. and AS7. encoders, perform a wobble measurement in accordance with the section "Measuring wobbling" ( 2 29). 7.3 Measuring wobbling Fault exclusion of the mechanical motor-encoder connection according to EN requires that the encoder is seated properly. Wobbling must be measured each time an ES7S, AS7W, or AS7Y encoder is installed to ensure it is seated properly. In the case of the EG7S, AG7W, and AG7Y encoders, no wobble measurement is necessary because the correct seating of the encoder is ensured by design. Measure wobbling as described in the following section Encoders for (E)DR , (E)DRN80 132S 1. Place the sensor on the upper edge of the encoder as shown in the figure below. > 5 mm The measurement must be carried out within the marked zone (maximum width = 5 mm). Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 29

30 7 Inspection/maintenance Measuring wobbling 3. Turn the motor shaft. If required, start up the motor at low speed (< 60 min -1 ). 4. Check the wobble on the sensor. ð The maximum permitted wobble on the encoder must be 0.07 mm when turning the motor shaft. Measured value exceeded [B] [F] [D] [362] [A] [B] [G] [619] [220] [35] [34] [361] [34] Tapping screw [A] Retaining screws on the torque bracket [35] Fan guard [B] Central retaining screw [220] Encoder [D] Cone [361] Safety cover [F] Bore [362] Expansion anchor [G] Tooth lock washer [619] Connection cover Repeat the check if the measured value is exceeded. Proceed as follows: 1. Loosen the screws of the connection cover [619] and remove it. Do not disconnect the encoder cable. 2. Make sure the cone [D] doesn t fall out while the central retaining screw [B] is loosened. Loosen the central retaining screw [B] by 2 3 turns. Loosen the cone [D] by tapping lightly onto the screw head. 3. Turn the motor shaft or the encoder shaft at the bore [F] by Tighten the central retaining screw [B] with the inserted tooth lock washer [G]. ð Tightening torque 2.75 Nm. ð Tolerance ±10 %. 5. Screw on the connection cover [619]. ð Tightening torque 2.25 Nm. ð Tolerance ±10 %. 6. Repeat the wobble measurement. 30 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

31 Inspection/maintenance Inspection and maintenance intervals 7 INFORMATION If it is not possible to carry out the measurement below the permitted wobble, contact the SEW EURODRIVE Service. 7.4 Inspection and maintenance intervals Inspect and service the safety brake according to the projected inspection and maintenance intervals or every 0.5 to 2 years depending on the load conditions. If a diagnostic unit /DUE is used, the wear output of the evaluation unit indicates whether brake maintenance is required. You may use the analog signal which is proportional to the air gap to plan brake maintenance. INFORMATION The amount of wear depends on many factors and may therefore be high. The system manufacturer must determine the required inspection/maintenance intervals individually in accordance with the project planning documents. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 31

32 7 Inspection/maintenance Safety brake 7.5 Safety brake INFORMATION SEW EURODRIVE recommends ordering the SEW EURODRIVE service to carry out the maintenance work. If you perform maintenance work yourself, the responsibility and the liability for the proper fulfillment of the work described in the relevant documentation is passed to the user; see the section Functional safety. Type of work Work permitted? Comments Replacing safety brake. Yes Replacement with structurally identical safety brake incl. options. Replacing existing BE.. brake with BE.. safety brake. Changing the braking torque. Checking and correcting the air gap, if necessary. Replacing individual parts of the BE.. safety brake. No Yes Yes Yes Replacing driver. Yes Retrofitting manual brake release /HR. Replacing manual brake release /HR. No Yes Deviating product designs require a check of the configuration as well as the suitability for the relevant application. Contact SEW EURODRIVE. Replacement of safety brake necessary. Observe minimum permitted brake disk thickness. See the section "Working air gap" ( 2 47). Replacement of the following individual parts is permitted: Sealing strip [66] Clamping strap [157], if necessary Sealing ring [95] Hex nut [61] Contact SEW EURODRIVE. Retrofitting diagnostic Yes Replacement of safety brake necessary. unit /DUE. 1) Replacing diagnostic Yes unit /DUE. 1) Retrofitting brake monitoring /DUB. 1) Yes Replacing brake Yes monitoring /DUB. 1) Replacement of safety brake necessary. 32 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

33 Inspection/maintenance Safety brake 7 Type of work Work permitted? Comments Setting brake monitoring Yes /DUB (switching point). 1) 1) Insofar as the option is available. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 33

34 7 Inspection/maintenance Preliminary work for motor and brake maintenance 7.6 Preliminary work for motor and brake maintenance General information Proceed as described in the respective documentation to remove and install the encoder/safety encoder and/or forced cooling fan. Before you complete the maintenance work, restore all protection devices at the drive. INFORMATION Observe the following points for inspection and maintenance: When replacing the safety brake due to a defect of the brake coil, always replace the brake control as well. Observe the information in the respective operating instructions. INFORMATION For all numbers of spare parts needed during maintenance work (e.g. screws [900]), refer to the respective exploded view drawings in the relevant operating instructions Wearing parts NOTICE Use of incorrect wear parts or a brake differing from the original. Loss of the safety function. Replace the brake only with an identical brake including all options as delivered from SEW EURODRIVE. If the brake is replaced, replace the following wear parts: Screws [900] (only (E)DRN71 with BE03, (E)DR , (E)DRN90 225) Gasket [392] (only (E)DR , (E)DNR71 80) Sealing ring [95] O-ring [901] (only (E)DR , (E)DRN132M 225) Gasket [901] (only (E)DR , (E)DRN63 71, (E)DRN90 312S) Motor tie rods [13] (only (E)DR , (E)DRN71 80) In case of visible wear or damage to the driver, also replace the following parts: Driver [70] Key [71] Retaining ring [62] Order these wear parts from SEW EURODRIVE prior to the brake replacement. INFORMATION To order the correct design of the brake and the wear parts, the item number of the spare and/or wearing parts and the serial number of the drive (see motor nameplate) are required. 34 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

35 Inspection/maintenance Preliminary work for motor and brake maintenance Order information for operating supplies and auxiliary material for maintenance The following table lists the various operating supplies and auxiliary materials that are required for correct maintenance. Use Manufacturer Operating supply/auxiliary material Part number Quantity Place of use Motors Sealing compound Marston-Domstel SEW L-Spezial g [550] All designs Thread locking compound Henkel Loctite 241 [13] [900] (E)DR (E)EDRN63 80 DR (E)DR (E)DRN90 132L Loctite 243 [900] (E)DR (E)DRN Anti-corrosion agent SEW EURODRIVE NOCO fluid g [70] All designs Observe the operating instructions for the particular motor regarding the lubrication of the radial oil seals on the motor and of the motor rolling bearings Identification of safety encoder If the drive is equipped with an encoder, you must remove it prior to the motor and brake maintenance. Please note that the work steps for an encoder with safety technology (safety encoder) differ from an encoder without safety technology (standard encoder). For this reason, check the FS logo on the motor nameplate, to find out if it is a safety encoder and observe the corresponding documentation: Drive with safety encoder = FS 04, FS 07, FS 11 Proceed as described in this addendum to the operating instructions to remove and install the encoder. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 35

36 7 Inspection/maintenance Working steps for inspecting (E)DR , (E)DRN63 315, DR brakemotors 7.7 Working steps for inspecting (E)DR , (E)DRN63 315, DR brakemotors INFORMATION If the drive is equipped with surface protection and corrosion protection, you must reestablish those measures after any work on the drive Measuring the working air gap of BE03 brakes The working air gap cannot be adjusted. The working air gap can only be measured via the stroke of the pressure plate when the brake is released. ü Disconnect the motor and all mounted options from the power supply before starting to work, and secure the motor against unintentional power-up. 1. Measure the working air gap X of the BE03 brake using a depth gauge or a slide gauge at the stroke of the studs. X ð The maximum permitted working air gap is 0.65 mm. Replace the brake in case this value is exceeded Setting the working air gap of brakes BE05 BE32 ü ü Disconnect the motor and all mounted options from the power supply before starting to work, and secure the motor against unintentional power-up. First identify if a safety encoder is present. Refer to the section "Identification of safety encoder" ( 2 35) for further information. 1. If present, remove the fan guard [35], the forced cooling fan [170], and the encoder [220]. 2. Shift the sealing strip [66]. To do so, release the clamping straps [157] if necessary. 36 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

37 Inspection/maintenance Working steps for inspecting (E)DR , (E)DRN63 315, DR brakemotors 7 3. Measure the working air gap A with a feeler gauge according to the figure at 3 points offset by 120. A Gather the correct values from the section "Switching work, working air gap, braking torques of the safety brakes" ( 2 47). ð If the correct value for the working air gap is exceeded or too low, correct it according to the documentation or contact the SEW EURODRIVE Service to set the working air gap correctly. 5. Remove the brake abrasion. 6. Install the sealing strip [66] and, if necessary, the clamping straps [157]. 7. Install the fan guard [35] or the forced cooling fan [170]. 8. Install the disassembled parts. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 37

38 7 Inspection/maintenance Brake exchange 7.8 Brake exchange A precise description of the brake exchange can be found in the relevant operating instructions. In the case of safety brakes, observe the following tightening torques and use Loctite to lock the threads. Motors Screw Tightening torque in Nm 1) Loctite (E)DRN63 71 DR (E)DR (E)DRN80 (E)DR (E)DRN (E)DR (E)DRN S (E)DR..160 (E)DRN132M/L (E)DR..180 (E)DRN (E)DR (E)DRN ) Tolerance ±10 % M M M M M M M Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

39 Inspection/maintenance Diagnostic unit /DUE for function and wear monitoring Diagnostic unit /DUE for function and wear monitoring The evaluation unit has a 5-pin DIP switch that is labeled with the numbers 1 to 5. Use it to set the measuring range and the maximum permitted wear limit (maximum working air gap). To activate the DIP switch 1, push the switch upwards. To deactivate the DIP switch 0, push the switch downwards. The table in the section "DIP switch setting values for option /DUE" ( 2 40) shows the DIP switch settings of the evaluation unit for the maximum working air gap if a safety brake is present. 1. Check the set value. Correct the setting value according to the following tables, if necessary. 2. Check the setting values of the DIP switches and calibrate the infinite value again, if necessary. Refer to the corresponding operating instructions for detailed instructions. INFORMATION Set the DIP switch only in a de-energized state. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 39

40 7 Inspection/maintenance Diagnostic unit /DUE for function and wear monitoring DIP switch setting values for option /DUE The following tables show the setting values of the DIP switches for the option /DUE when the brake is designed as a safety brake or in combination with a safety encoder. S1 S2 S3 S4 S5 Wear limit BE1 2 BE5 Sensor Ø 6 mm mm mm mm mm mm mm X mm X mm S1 S2 S3 S4 S5 Wear limit BE11 30 BE32 Sensor Ø 8 mm mm mm mm mm mm X mm X mm mm S1 S2 S3 S4 S5 Wear limit BE60 BE62 BE122 Sensor Ø 8 mm mm mm mm mm X mm X mm X mm mm X Factory setting Setting possible in addition 40 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

41 Technical data Safety encoder 8 8 Technical data 8.1 Safety encoder Characteristic safety values INFORMATION In addition to the documentation, you can also obtain the characteristic safety values of components by SEW-EURODRIVE in the SEW-EURODRIVE library for the SIS- TEMA software tool. The documentation and the library are available for download from Characteristic safety values ES7S, EG7S Characteristic safety values according to EN 62061/IEC EN ISO Classification/underlying standards SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) PFH d value 1) (without mounting on the motor) MTTF D value 1) (without mounting on the motor) PFH d value 1) (with mounting on the motor; takes into account a derating due to motor reheating) MTTF d value 1) (with mounting on the motor; takes into account a derating due to motor reheating) Service life/proof test interval Motor/encoder connection (only for drives with FS logo) 8.5 x /h = 8.5 FIT (T amb 45 C) 1.3 x /h = 13 FIT (T amb 60 C) 1306 years (T amb 45 C) 895 years (T amb 60 C) 5.0 x /h = 50 FIT (T amb 60 C) 212 years (T amb 60 C) 20 years Fault exclusion according to EN ) The specified values are valid if the requirements to the evaluation unit according to section "Requirements to the follow-up electronics" are adhered to. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 41

42 8 Technical data Safety encoder Characteristic safety values AS7W, AG7W, AS7Y, AG7Y Characteristic safety values according to EN 62061/IEC EN ISO Classification/underlying standards SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) PFH d value 1) (without mounting on the motor) MTTF d value 1) (without mounting on the motor) PFH d value 1) (with mounting on the motor; takes into account a derating due to motor reheating) MTTF d value 1) (with mounting on the motor; takes into account a derating due to motor reheating) Service life/proof test interval Motor/encoder connection (only for drives with FS logo) /h = 9.3 FIT (T amb 45 C) /h = 14 FIT (T amb 60 C) 1155 years (T amb 45 C) 753 years (T amb 60 C) 5.0 x /h = 50 FIT (T amb 60 C) 212 years (T amb 60 C) 20 years Fault exclusion according to EN ) The specified values are valid if the requirements to the evaluation unit according to section "Requirements to the follow-up electronics" are adhered to. Characteristic safety values for EI7C FS Characteristic safety values according to EN EN ISO Safety class/underlying standards SIL 2 PL d System structure HFT = 0 Category 2 (cat. 2) PFH d value 8.0 x /h = 80 FIT (T amb 60 C) MTTF d value 202 years (T amb 60 C) Service life/proof test interval 20 years Safe fault coverage (SFF) 95% 42 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

43 Technical data Safety encoder Encoders ES7S, EG7S, AS7Y, AG7Y, AS7W, AG7W Designation Value Operating temperature of encoder -30 C +85 C Ambient temperature of motor DR.., EDR C +40 C DR2.., DRN.., EDRN C +60 C Storage temperature -15 C +70 C Maximum speed Vibration resistance (EN ) /min 100 m/s 2 10 g (at 10 Hz to 2 khz) Maximum angular acceleration 10 4 rad/s 2 Degree of protection (EN 60529) IP66 ES7S, EG7S Designation Operating voltage Max. current consumption Value DC 7 V 30 V ES7S: 140 ma EG7S: 140 ma Resolution sin/cos interface 1024 periods/revolution Accuracy (70 angular seconds) 1) Shock resistance (EN ) ES7S: 1000 m/s g (6 ms) EG7S: 2000 m/s g (6 ms) Duration until fault message 2) (deactivated outputs) 25 ms 1) Due to the stiffness of the torque bracket, you have to take into account an automatically resetting ±0.6 twist (depending on the direction of rotation) of the encoder housing compared to the encoder shaft. 2) The ES7S and EG7S sine/cosine encoders have a self-diagnostics function. If an error is detected, the sensor reports it by deactivating the output signals to the encoder evaluation unit. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 43

44 8 Technical data Safety encoder AS7Y, AG7Y Designation Operating voltage Max. current consumption Value DC 7 V 30 V AS7Y: 150 ma AG7Y: 150 ma Resolution of the incremental section sin/cos interface 2048 periods/revolution Accuracy of the incremental section (70 angular seconds) 1) Resolution of the absolute section SSI interface, gray-coded 12 bit = 4096 revolutions (single-turn) 12 bit = 4096 revolutions (multi-turn) Accuracy of the absolute section Clock frequency of the absolute section Shock resistance (EN ) ±1 LSB (Least Significant Bit) 100 khz to 800 khz AS7Y: 1000 m/s g (6 ms) AG7Y: 2000 m/s g (6 ms) Duration until fault message 2) (deactivated outputs) 25 ms + 3/4 revolution 1) Due to the stiffness of the torque bracket, you have to take into account an automatically resetting ±0.6 twist (depending on the direction of rotation) of the encoder housing compared to the encoder shaft. 2) The AS7Y and AG7Y absolute encoders have a self-diagnostics function. If an error is detected, the sensor reports it by deactivating the output signals to the encoder evaluation unit. AS7W, AG7W Designation Operating voltage Max. current consumption Value DC 7 V 30 V AS7W: 140 ma AG7W: 140 ma Resolution of the incremental section sin/cos interface 2048 periods/revolution Accuracy of the incremental section (70 angular seconds) 1) Resolution of the absolute section RS485 interface 13 bit = 8192 revolutions (single-turn) 16 bit = increments (multi-turn) Accuracy of the absolute section ±1 LSB (Least Significant Bit) Shock resistance (EN ) AS7W: 1000 m/s g (6 ms) AG7W: 2000 m/s g (6 ms) Duration until fault message 2) (deactivated outputs) 25 ms + 3/4 revolution 1) Due to the stiffness of the torque bracket, you have to take into account an automatically resetting ±0.6 twist (depending on the direction of rotation) of the encoder housing compared to the encoder shaft. 2) The AS7W and AG7W absolute encoders have a self-diagnostics function. If an error is detected, the sensor reports it by deactivating the output signals to the encoder evaluation unit. 44 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

45 Technical data Safety encoder 8 EI7C FS Supply min. Typ. max. Unit Operating voltage 1) V B V Max. current consumption (with no load) I max (V B = 24 V, I out = 0) 120 ma 1) The voltage supply must come from SELV/PELV circuits in accordance with DIN EN Name Value Max. speed n max 3600 min -1 HTL periods per revolution N periods 24 Ambient temperature T A 0 C to +60 C Vibration resistance Acc. to EN : g (98.1 m/s 2 ); Hz Shock resistance Acc. to EN : g (981 m/s 2 ); 6 ms Degree of protection Acc. to EN IP66 Connection M12 (8-pole) Maximum angular acceleration 3000 rad/s 2 Permitted magnetic interference field on the outer contour of the motor B extmax H extmax 25 mt 20 ka/m Signal tracks min. Typ. max. Unit Output amplitude per track V high (I out = I out_max ) V low (I out = I out_max ) V B 3.5 V B V 0 +3 V Max. output current per track I out_max ±30 ma Tolerance signal period (corresponds to the speed tolerance) Track A:B phase offset φ Period.tol (n = constant) φ Phase.A:B (n = constant) % Degree Pulse duty factor (DIN IEC ) t = t log_1 /(t period ) (n = constant) % Pulse frequency for maximum speed (maximum speed periods) Output leakage current in deactivated state (= error message) 1) f max 1.44 khz I Error +250 µa Start-up time (undefined outputs) From V B > 9 V 300 ms Duration until error message ms (deactivated outputs) 1) 1) The EI7C FS built-in encoder has a self-diagnostics function. If an error is detected, the system reports it by deactivating the output signals to the encoder evaluation unit. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 45

46 8 Technical data Safety brake 8.2 Safety brake Braking work until maintenance Braking work BE.. brake until inspection (W insp ) 10 6 J Braking work BE.. safety brake until inspection (W insp ) 10 6 J FS code FS04, FS07 FS02 FS11 Brake BE BE BE BE BE BE BE BE BE BE BE BE BE Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

47 Technical data Safety brake Working air gap The following values apply when the brake is designed as a safety brake or to brakes in combination with a safety encoder. Brake Working air gap Brake lining carrier mm mm min. 1) max. min. BE ) BE BE BE BE BE BE BE BE BE60 3) BE62 3) BE120 3) BE122 3) ) When checking the working air gap, note: After a test run, parallelism tolerances on the brake lining carrier may give rise to deviations of ±0.15 mm. 2) The brake lining carrier of the BE03 cannot be replaced. Replace the brake when the maximum working air gap is reached. 3) Brake not available as a safety brake. Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 47

48 8 Technical data Safety brake Safety characteristics INFORMATION In addition to the documentation, you can also obtain the characteristic safety values of components by SEW-EURODRIVE in the SEW-EURODRIVE library for the SIS- TEMA software tool. The documentation and the library are available for download from Characteristic safety values for BE.. safety brakes Classification Category 1 System structure 1-channel (Cat. 1) Characteristic safety values according to EN ISO Operating mode Safe state Safety functions High demand Brake applied Safe brake actuation (SBA) Safe brake hold (SBH) Service life T 10D value MTTF d value 20 years or T 10D value (depending on which value occurs first) 0.1 MTTF D Calculation via B 10D value B 10d value BE BE BE BE BE BE BE BE BE Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

49 Technical data Safety brake Brake controls Combinations of brake controls The tables below show the standard and optional combinations of safety brake and brake rectifiers. Installation in control cabinet Type designation Voltage range V BE03 BE05 BE1 BE2 BE5 BE11 BE20 BE30 BST 0.6S AC 460 X X X X X X X BST 0.7S AC 400 X X X X X X X BST 1.2S AC 230 X X X X X X X BMS 1.4 AC BMS 1.5 AC BMS 3 AC BME 1.4 AC BME 1.5 AC BME 3 AC BMP 1.4 AC BMP 1.5 AC BMP 3 AC BMK 1.4 AC BMK 1.5 AC BMKB 1.5 AC BMK 3 AC BMH 1.4 AC BMH 1.5 AC BMH 3 AC BMV 5 DC 24 X Standard version Selectable Not permitted BE32 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 49

50 8 Technical data Safety brake Installation in the motor wiring space Type designation Voltage range V BE03 BE05 BE1 BE2 BE5 BE11 BE20 BE30 BG 1.2 AC X BG 1.4 AC Size 1.5 AC BG 2.4 AC X BG 3 AC BGE 1.4 AC BGE 1.5 AC BGE 3 AC BSG DC 24 BS 24 DC 24 X Standard version Selectable Not permitted BE32 50 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

51 Checklists Checklist for encoder assembly 9 9 Checklists The checklists allow you to document the performed and safety-related tasks when exchanging a safety brake or safety encoder. The checklist for brake assembly applies only to motors of size 80 or higher. The checklist for encoder assembly applies to motors of all sizes. 9.1 Checklist for encoder assembly Drive and encoder data Technician: Date: Drive designation: Motor serial number: Encoder part number: Encoder serial number: Required resources: For the encoders ES7S, AS7W, AS7Y, a new expansion anchor (part number: ) NOCO fluid (part number: ) Loctite 241 Various sizes of hollow hexagon wrenches Various sizes of external hexagon wrenches Torque wrench for tightening torques of 2.0 Nm to 8.0 Nm Sensor for measuring the wobble with a measuring range in the 1/100-mm range (for (E)DR , (E)DRN80 132S motors only) Checklist for (E)DR /(E)DRN80 132S motor Performed task Encoder pin coated with NOCO fluid Central retaining screw [B] of the encoder tightened (tightening torque 2.75 Nm ±5 %) Expansion anchor [362] pressed into the fan guard [35] Retaining screws on the torque bracket [A] tightened into the expansion anchor [362] (tightening torque 2.25 Nm ±10 %) Wobble measurement performed (tolerance 0.07 mm) Connection cover [619] screwed in place (tightening torque 2.25 Nm ±10 %) Safety cover [361] mounted Checklist for (E)DR /(E)DRN132M 280 motor Performed task Encoder pin coated with NOCO fluid Central retaining screw [B] of the encoder tightened (tightening torque 8 Nm ±5 %) Retaining screws on the torque bracket [232] moistened with Loctite 241 Retaining screws on the torque bracket [232] tightened (tightening torque 6 Nm ±10 %) Connection cover [619] screwed in place (tightening torque 2.25 Nm ±10 %) Safety cover [361] mounted Finished Finished Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 51

52 9 Checklists Checklist for brake assembly 9.2 Checklist for brake assembly Drive and brake data Technician: Date: Drive designation: Motor serial number: Brake: Brake identification number: Brake working air gap 3x: Motor size Required wear parts Quantity All sizes Brake premounted [550], key [71], driver [70], retaining ring [62] 1x each (E)DR..80, (E)DRN80, DR2..80 Gasket [392] 1 (E)DR , (E)DRN O-ring/gasket [901] 1 (E)DR..80, (E)DRN80, DR2..80 Screws [13] 4 (E)DR , (E)DRN Screws [900] 4 (E)DR , (E)DRN80 225, DR2..80 Sealing ring [95] 1 Performed task (E)DR..80 (E)DRN80 DR2..80 (E)DR (E)DRN90 132S (E)DR (E)DRN132M 225 Key [71] installed in rotor Driver [70] installed on rotor Retaining ring [62] to secure the driver [70] installed Gasket [392] placed on stator O-ring/gasket [901] placed on stator Brake cable of the brake [550] fed into terminal box Brake [550] placed on motor Screws [13] moistened with Loctite 241 and secured; tightening torque 5 Nm Screws [900] moistened with Loctite 241/243 and secured (tightening torque: M6 = 10.3 Nm, M8 = 25.5 Nm, M10 = 50 Nm, M12 = 87.3 Nm) Gasket [95] mounted Brake connector [698] connected Brake connected in terminal box 52 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

53 Index Index Icons (Dis)assembly work... 27, 32 (Dis)assembly, encoder /TF B BE.. brake Motor combinations Motor/brake assignment Brake Braking torque graduations Maintenance intervals Brake diagnostics Brake maintenance Brake rectifier combinations Brake replacement Braking torques D Diagnostic unit /DUE E EI7C FS encoder connection EI7C FS visual feedback F Functional safety... 27, 32 (Dis)assembly work... 27, 32 Sealing... 27, 32 I Inspecting the brakemotor DR , DRN63 315, DR Inspection and maintenance work Inspection intervals M Maintenance intervals Mechanical installation Manual brake release /HR Motor maintenance, preliminary work Motor/brake assignment P Perform concentricity test Perform wobble measurement Personnel, qualified R Removing/installing the encoder Replacing the brake S Safety notes Preliminary information... 6 Service... 27, 32 T Technical data AS7W / AG7W AS7Y / AG7Y Braking torque graduations Braking work until maintenance, working air gap for BE..(FS) brake EI7C FS Encoder ES7S / EG7S Temperature sensor /TF W Wear Working air gap /EN 08/18 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors 53

54 10 Glossary 10 Glossary B 10D Number of cycles until 10% of the components endanger through failure (for pneumatic and electromechanical components) Cat. Category CCF Common cause failure DC Diagnostic coverage DC avg Average diagnostic coverage FS Functional safety MTTFd Mean time to dangerous failure PFH d Mean probability of a dangerous failure per hour PL Performance level PLr Required Performance Level SAR Safe Acceleration Range safety function SBA Safe Brake Actuation safety function SBC Safe Brake Control safety function SBH Safe Brake Hold safety function SBS Safe brake system SDI Safe Direction safety function SIL Safety integrity level SISTEMA Software of the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA) for determining the performance level. SLI Safely Limited Increment safety function SLS Safely Limited Speed safety function SS1 Safe Stop 1 safety function SSM Safe Speed Monitor safety function STO Safe Torque Off safety function T 10d Mean time until 10% of the parts have failed dangerously 54 Addendum to the Operating Instructions DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors

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